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  High performance lubricant additivesRelated Patent Categories: Solid Anti-friction Devices, Materials Therefor, Lubricant Or Separant Compositions For Moving Solid Surfaces, And Miscellaneous Mineral Oil Compositions, Lubricants Or Separants For Moving Solid Surfaces And Miscellaneous Mineral Oil Compositions (e.g., Water Containing, Etc.), Nitrogen And Heavy Metal, Or Nitrogen And Aluminum, In The Same Compound, The Nitrogen Is Bonded Directly To The Carbon Of A -c(=x)x- Group, Wherein The X`s May Be The Same Or Diverse Chalcogens (e.g., Dithiocarbamates, Etc.)The Patent Description & Claims data below is from USPTO Patent Application 20070093397. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD [0001] The present application relates generally to lubricant additives and, more particularly, to high-performance lubricant additives that enhance desirable lubricant properties of lubricants. BACKGROUND OF THE INVENTION [0002] Lubricants comprise a variety of compounds selected for desirable characteristics such as anti-wear and anti-friction properties. Often commercial lubricants are compositions containing a lubricant base such as a hydrocarbon oil or grease, to which is added numerous lubricant additives selected for additional desirable properties. Lubricant additives may enhance the lubricity of the lubricant base and/or may provide anti-wear or other desirable characteristics. [0003] Lubricants are used in enormous quantities. For example, more than four billion quarts of crankcase oil are used in the United States per year. However, many lubricants currently in use also have undesirable characteristics. Currently available crankcase oils generally include the anti-wear additive zinc dialkyldithiophosphate (ZDDP), which contains phosphorous and sulfur. Phosphorous and sulfur poison catalytic converters causing increased automotive emissions. It is expected that the EPA eventually will mandate the total elimination of ZDDP or will allow only extremely low levels of ZDDP in crankcase oil. However, no acceptable anti-wear additives to replace ZDDP in engine oils are currently available. [0004] Additionally, lubricant bases used in conventional lubricants usually have lubricant additives added to them to improve lubricity. Many of these lubricant additives do not provide sufficient additional lubricity and/or possess additional undesirable characteristics. [0005] Accordingly, it is an object of the present invention to provide environmentally-friendly anti-wear additives for lubricants, wherein the amounts of phosphorous and sulfur in the anti-wear additive are significantly reduced and approach zero. It is another object of the present invention to produce compounds with desirable anti-wear and anti-friction characteristics. BRIEF SUMMARY OF THE INVENTION [0006] Embodiments of the invention comprise methods for preparing lubricant additives and lubricants by reacting together organophosphates such as zinc dialkyldithiophosphate (ZDDP) and organofluorine compounds such as polytetrafluoroethylene (PTFE). PTFE used with embodiments of the present invention comprises more than 40 carbon atoms. In one embodiment, ZDDP and PTFE are reacted together at about -20.degree. C. to about 150.degree. C. In a preferred embodiment, ZDDP and PTFE are reacted together at a temperature of about 60.degree. C. to about 150.degree. C. The reaction is allowed to continue from about 20 minutes to about 24 hours. Both supernatants and precipitates formed during the reaction may be used as lubricant additives. These lubricant additives may be added to lubricants such as oils, greases, automatic transmission fluids, crankcase fluids, engine oils, hydraulic oils, and gear oils. In certain embodiments, organophosphates and organofluorine compounds can be added to a lubricant base and then allowed to react under specified conditions. [0007] Other embodiments of the present invention react a mixture of powdered, masticated metal halide with an organophosphate such as ZDDP and an organofluorine such as PTFE to form a lubricant additive or lubricant. In yet other embodiments, other forms of metal halide may be used that are not powdered and/or masticated. The metal halide used is metal fluoride in a preferred embodiment of the invention. In a preferred embodiment, the metal fluoride, ZDDP and PTFE are reacted together at about -20.degree. C. to about 150.degree. C. to form a lubricant additive. The lubricant additive is then added to a lubricant. The lubricants to which the lubricant additive is added are preferably fully formulated GF4 engine oils without ZDDP. However, other lubricants may be used such as those listed above. [0008] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized that such equivalent constructions do not depart from the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS [0009] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which: [0010] FIG. 1 is a table of possible organophosphate formulas used with certain embodiments of the present invention; [0011] FIGS. 2A-D show various organophosphate structures used with certain embodiments of the present invention; [0012] FIG. 3 shows PTFE structures used with certain embodiments of the present invention; [0013] FIGS. 4A and 4B show reaction products of certain embodiments of the present invention; [0014] FIGS. 5A-5C show graphs illustrating the results of ASTM D2596 4-Ball Weld Load experiments in which lubricant grease containing various quantities of ZDDP, PTFE, catalyst, and/or molybendum disulfide were present; [0015] FIGS. 6A and 6B are charts summarizing the results of ASTM D2596 4-Ball Weld Load experiments used to generate the cube graphs of FIGS. 5A-5C; [0016] FIG. 7 is a graph summarizing the results of a block on cylinder test for various lubricants; [0017] FIG. 8 is a graph of experimental results from a block on cylinder test comparing several grease compositions; [0018] FIG. 9 shows 3 dimensional predictions of wear scar dimensions based on experimental results from block on cylinder tests comparing grease compositions; [0019] FIG. 10 shows the results of differential scanning calorimetry (DSC) tests to determine the decomposition temperatures of ZDDP; and [0020] FIG. 11 shows wear volume test results for engine oils from a ball on cylinder test. 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